Komatsu Hydraulic Excavator Pc490lc 11 Usa Shop Manual

CEBM028301
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Shop
Manual

PC490LC-11
HYDRAULIC EXCAVATOR

SERIAL NUMBERS PC490LC-11 A41001 and up

ENGINE 6D125E-7

This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.

Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.

Copyright 2014 Komatsu

Printed in U.S.A.
Komatsu America Corp.
September 2014

This is the cut pages sample. Download all 2662 page(s) at: ManualPlace.com
 00 INDEX AND FOREWORD

PC490LC-11 00-1
INDEX 00 INDEX AND FOREWORD

INDEX
00 INDEX AND FOREWORD ........................................................................................................................ 00-1
FOREWORD, SAFETY, BASIC INFORMATION ................................................................................... 00-19
HOW TO READ THE SHOP MANUAL........................................................................................... 00-19
SAFETY NOTICE FOR OPERATION............................................................................................. 00-21
ACTION IF FIRE OCCURS............................................................................................................ 00-27
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS ........................................................ 00-28
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS...................................................... 00-29
PRECAUTIONS FOR AdBlue/DEF ................................................................................................ 00-30
STORE AdBlue/DEF ...................................................................................................................... 00-31
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT ...................................................... 00-32
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS................................ 00-34
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT..................................................... 00-40
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT .................................................. 00-43
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT .............................................. 00-44
PRACTICAL USE OF KOMTRAX .................................................................................................. 00-45
METHOD FOR DISCONNECTING AND CONNECTING PUSH-PULL TYPE COUPLER .............. 00-46
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS ..................... 00-49
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR ..................... 00-53
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR ....... 00-54
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL ... 00-56
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH .. 00-57
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE .
................................................................................................................................................... 00-59
HOW TO READ ELECTRICAL WIRE CODE ................................................................................. 00-60
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.................................................... 00-64
LIST OF ABBREVIATION .............................................................................................................. 00-67
STANDARD TIGHTENING TORQUE TABLE................................................................................. 00-72
CONVERSION TABLE ................................................................................................................... 00-79
01 SPECIFICATION....................................................................................................................................... 01-1
CONTENTS ............................................................................................................................................ 01-2
SPECIFICATIONS .................................................................................................................................. 01-3
SPECIFICATION DRAWING............................................................................................................ 01-3
WORKING RANGE DRAWINGS ..................................................................................................... 01-5
SPECIFICATIONS ........................................................................................................................... 01-6
WEIGHT TABLE .............................................................................................................................. 01-9
TABLE OF FUEL, COOLANT, AND LUBRICANTS .........................................................................01-11
10 STRUCTURE AND FUNCTION ................................................................................................................ 10-1
CONTENTS ............................................................................................................................................ 10-2
UREA SCR SYSTEM.............................................................................................................................. 10-5
LAYOUT DRAWING OF UREA SCR SYSTEM ................................................................................ 10-5
UREA SCR SYSTEM DIAGRAM ..................................................................................................... 10-9
FUNCTION OF UREA SCR SYSTEM............................................................................................ 10-10
COMPONENT PARTS OF UREA SCR SYSTEM........................................................................... 10-25
BOOT-UP SYSTEM .............................................................................................................................. 10-34
LAYOUT DRAWING OF BOOT-UP SYSTEM................................................................................. 10-34
SYSTEM OPERATING LAMP SYSTEM ........................................................................................ 10-36
BATTERY DISCONNECT SWITCH ............................................................................................... 10-37
ENGINE SYSTEM ................................................................................................................................ 10-38
LAYOUT DRAWING OF ENGINE RELATED PARTS ..................................................................... 10-38
ENGINE CONTROL SYSTEM ....................................................................................................... 10-41
AUTO-DECELERATION SYSTEM ................................................................................................. 10-44
ENGINE AUTOMATIC WARM-UP SYSTEM .................................................................................. 10-46
OVERHEAT PREVENTION SYSTEM ............................................................................................ 10-48
TURBOCHARGER PROTECTION SYSTEM ................................................................................. 10-51
AUTOMATIC IDLE STOP SYSTEM ............................................................................................... 10-53
COMPONENT PARTS OF ENGINE SYSTEM ............................................................................... 10-56

00-2 PC490LC-11
00 INDEX AND FOREWORD INDEX

COOLING SYSTEM.............................................................................................................................. 10-71

LAYOUT DRAWING OF COOLING SYSTEM ................................................................................ 10-71
FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN .............................................................. 10-74
ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN..................................................... 10-76
FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN......................................................... 10-79
COMPONENT PARTS OF COOLING SYSTEM............................................................................. 10-80
CONTROL SYSTEM............................................................................................................................. 10-94
LAYOUT DRAWING OF ELECTRICAL CONTROL SYSTEM ........................................................ 10-94
MACHINE MONITOR SYSTEM ..................................................................................................... 10-97
KOMTRAX SYSTEM...................................................................................................................... 10-98
COMPONENT PARTS OF CONTROL SYSTEM............................................................................ 10-99
HYDRAULIC SYSTEM.........................................................................................................................10-129
LAYOUT DRAWING OF HYDRAULIC COMPONENT...................................................................10-129
CLSS ............................................................................................................................................10-131
ENGINE AND PUMP COMBINED CONTROL SYSTEM...............................................................10-150
PUMP AND VALVE CONTROL SYSTEM .....................................................................................10-157
COMPONENT PARTS OF HYDRAULIC SYSTEM .......................................................................10-160
WORK EQUIPMENT SYSTEM ............................................................................................................10-247
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM ..............................................................10-247
STRUCTURE OF VALVE CONTROL............................................................................................10-252
ONE-TOUCH POWER MAXIMIZING SYSTEM ............................................................................10-253
MACHINE PUSH-UP SYSTEM .....................................................................................................10-255
PPC LOCK SYSTEM ....................................................................................................................10-257
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM ..............................................10-258
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT.................................................................10-260
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM ...........................................................10-262
SWING CONTROL SYSTEM...............................................................................................................10-278
LAYOUT DRAWING OF SWING SYSTEM ...................................................................................10-278
SWING CONTROL SYSTEM DIAGRAM ......................................................................................10-284
COMPONENT PARTS OF SWING SYSTEM................................................................................10-288
TRAVEL SYSTEM................................................................................................................................10-303
LAYOUT DRAWING OF TRAVEL SYSTEM ..................................................................................10-303
TRAVEL CONTROL SYSTEM DIAGRAM .....................................................................................10-307
COMPONENT PARTS OF TRAVEL SYSTEM ..............................................................................10-309
UNDERCARRIAGE AND FRAME........................................................................................................10-330
LAYOUT DRAWING OF UNDERCARRIAGE ................................................................................10-330
WORK EQUIPMENT............................................................................................................................10-331
STRUCTURE OF WORK EQUIPMENT ........................................................................................10-331
FUNCTION OF WORK EQUIPMENT ...........................................................................................10-332
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM............................................................10-333
BUCKET CLEARANCE ADJUSTMENT SHIM ..............................................................................10-334
CAB AND ITS ATTACHMENTS ...........................................................................................................10-335
ROPS CAB ...................................................................................................................................10-335
CAB MOUNT ................................................................................................................................10-336
CAB TIPPING STOPPER .............................................................................................................10-337
20 STANDARD VALUE TABLE ...................................................................................................................... 20-1
CONTENTS ............................................................................................................................................ 20-2
STANDARD VALUE TABLE FOR ENGINE ............................................................................................. 20-3
STANDARD VALUE TABLE FOR ENGINE: PC490LC-11 ................................................................ 20-3
STANDARD VALUE TABLE FOR MACHINE........................................................................................... 20-6
STANDARD VALUE TABLE FOR MACHINE: PC490LC-11 ............................................................. 20-6
STANDARD VALUE TABLE FOR ELECTRICAL ................................................................................... 20-26
STANDARD VALUE TABLE FOR ELECTRICAL ............................................................................ 20-26
30 TESTING AND ADJUSTING ..................................................................................................................... 30-1
CONTENTS ............................................................................................................................................ 30-2
RELATED INFORMATION ON TESTING AND ADJUSTING .................................................................. 30-5
TOOLS FOR TESTING AND ADJUSTING....................................................................................... 30-5
SKETCH OF TOOLS FOR TESTING AND ADJUSTING ................................................................30-11

PC490LC-11 00-3
INDEX 00 INDEX AND FOREWORD

ENGINE AND COOLING SYSTEM....................................................................................................... 30-12

TEST ENGINE SPEED .................................................................................................................. 30-12
TEST BOOST PRESSURE............................................................................................................ 30-14
TEST EXHAUST GAS COLOR ...................................................................................................... 30-16
TEST AND ADJUST VALVE CLEARANCE .................................................................................... 30-18
TEST COMPRESSION PRESSURE.............................................................................................. 30-21
TEST BLOWBY PRESSURE ......................................................................................................... 30-24
TEST ENGINE OIL PRESSURE .................................................................................................... 30-26
TEST EGR VALVE AND KVGT OIL PRESSURE ........................................................................... 30-28
TEST FUEL PRESSURE ............................................................................................................... 30-30
TEST FUEL RETURN RATE AND LEAKAGE................................................................................ 30-32
BLEED AIR FROM FUEL SYSTEM ............................................................................................... 30-35
TEST FUEL CIRCUIT FOR LEAKAGE .......................................................................................... 30-37
HANDLE CYLINDER CUT-OUT MODE OPERATION.................................................................... 30-39
HANDLE NO-INJECTION CRANKING OPERATION ..................................................................... 30-40
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION ................................. 30-41
CLEAN FUEL DOSER ................................................................................................................... 30-43
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER.................................. 30-45
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER ................ 30-51
TEST SCR RELATED FUNCTIONS............................................................................................... 30-52
CLEAN AdBlue/DEF TANK ............................................................................................................ 30-74
POWER TRAIN..................................................................................................................................... 30-78
TEST SWING CIRCLE BEARING CLEARANCE ........................................................................... 30-78
UNDERCARRIAGE AND FRAME......................................................................................................... 30-79
TEST AND ADJUST TRACK TENSION......................................................................................... 30-79
HYDRAULIC SYSTEM.......................................................................................................................... 30-81
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM............................................. 30-81
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS ........
................................................................................................................................................... 30-82
TEST OIL PRESSURE OF CONTROL CIRCUIT ........................................................................... 30-93
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT .................................... 30-95
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT..................................... 30-98
TEST OUTLET PRESSURE OF SOLENOID VALVE ....................................................................30-103
TEST PPC VALVE OUTLET PRESSURE .....................................................................................30-106
ADJUST WORK EQUIPMENT AND SWING PPC VALVES ..........................................................30-108
TEST PUMP SWASH PLATE SENSOR........................................................................................30-109
TEST COOLING FAN SPEED .....................................................................................................30-110
TEST OIL PRESSURE IN FAN PUMP CIRCUIT........................................................................... 30-111
TEST FAN PUMP EPC ELECTRIC CURRENT.............................................................................30-113
TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE ...............................................30-114
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT................................30-115
TEST OIL LEAKAGE ....................................................................................................................30-117
BLEED AIR FROM HYDRAULIC CIRCUIT ...................................................................................30-120
CAB AND ITS ATTACHMENTS ...........................................................................................................30-124
TEST CAB TIPPING STOPPER ...................................................................................................30-124
METHOD FOR ADJUSTING MIRRORS .......................................................................................30-125
ELECTRICAL SYSTEM .......................................................................................................................30-130
SETTING AND OPERATION OF MACHINE MONITOR................................................................30-130
METHOD FOR STARTING UP KOMTRAX ...................................................................................30-208
ADJUST REARVIEW CAMERA ANGLE .......................................................................................30-213
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER .....................................................30-216
HANDLE BATTERY DISCONNECT SWITCH ...............................................................................30-217
TEST DIODES ..............................................................................................................................30-218
Pm CLINIC...........................................................................................................................................30-219
Pm CLINIC SERVICE ...................................................................................................................30-219
40 TROUBLESHOOTING .............................................................................................................................. 40-1
CONTENTS ............................................................................................................................................ 40-2
RELATED INFORMATION ON TROUBLESHOOTING ......................................................................... 40-13

00-4 PC490LC-11
00 INDEX AND FOREWORD INDEX

GENERAL TROUBLESHOOTING POINTS ................................................................................... 40-13

TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM.......................................................... 40-14
SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................... 40-27
CHECKS BEFORE TROUBLESHOOTING.................................................................................... 40-29
CHECKS BEFORE TROUBLESHOOTING .................................................................................... 40-31
TESTING IN ACCORDANCE WITH TESTING PROCEDURE....................................................... 40-33
ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION ................................................. 40-54
PROCEDURE FOR TESTING AND TROUBLESHOOTING .......................................................... 40-64
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS ............................................. 40-67
INFORMATION IN TROUBLESHOOTING TABLE ......................................................................... 40-71
CONNECTOR LIST AND LAYOUT ................................................................................................ 40-73
CONNECTOR PIN NUMBERS - CONNECTION TABLE................................................................ 40-86
T-BOXES AND T-ADAPTERS LIST ..............................................................................................40-125
FUSE LOCATION TABLE .............................................................................................................40-131
PRECAUTIONS FOR KDPF (KCSF, KDOC) CLEANING AND CHANGE .....................................40-133
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883]
AND [CA3135])..........................................................................................................................40-137
FAILURE CODES TABLE .............................................................................................................40-139
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .....................................................40-157
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit.....................40-157
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit .....................40-158
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit ................................40-159
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit ................................40-161
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit..........................................................40-163
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit..........................................................40-164
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit.....................................40-165
FAILURE CODE [879EMC] Ventilation Damper Malfunction .........................................................40-167
FAILURE CODE [879FMC] Air Mix Damper Malfunction...............................................................40-168
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range ................................40-169
FAILURE CODE [989L00] Engine Controller Lock Caution 1 ........................................................40-171
FAILURE CODE [989M00] Engine Controller Lock Caution 2 .......................................................40-172
FAILURE CODE [989N00] Engine Controller Lock Caution 3........................................................40-173
FAILURE CODE [A1U0N3] HC Desorb Request 1 ........................................................................40-174
FAILURE CODE [A1U0N4] HC Desorb Request 2 ........................................................................40-176
FAILURE CODE [A900FR] Abrupt Engine Stop by Auto Idling Stop 3...........................................40-178
FAILURE CODE [A900N6] Abrupt Engine Stop by Auto Idling Stop 1...........................................40-179
FAILURE CODE [A900NY] Abrupt Engine Stop by Auto Idling Stop 2 ..........................................40-180
FAILURE CODE [AA10NX] Air Cleaner Clogging..........................................................................40-181
FAILURE CODE [AB00KE] Charge Voltage Low...........................................................................40-183
FAILURE CODE [AQ10N3] Manual Stationary Regeneration Request (KDOC Face Plugging) ....40-186
FAILURE CODE [AS00N3] Manual Stationary Regeneration Request (SCR) ...............................40-188
FAILURE CODE [AS00R2] Warning 2 (SCR Device Abnormality) ................................................40-190
FAILURE CODE [AS00R3] Inducement 1 (SCR Device Abnormality) ...........................................40-191
FAILURE CODE [AS00R4] Inducement 2 (SCR Device Abnormality) ...........................................40-192
FAILURE CODE [AS00R5] Inducement 3 (SCR Device Abnormality) ...........................................40-193
FAILURE CODE [AS00R6] Temporary Recovery of Inducement...................................................40-194
FAILURE CODE [AS00ZK] AdBlue/DEF Level Low Error 5...........................................................40-195
FAILURE CODE [AS10KM] AdBlue/DEF Injector Overheat Warning ............................................40-196
FAILURE CODE [AS10NR] AdBlue/DEF Injector High Temperature Warning ...............................40-197
FAILURE CODE [AS10NT] AdBlue/DEF Injector Overheat Caution..............................................40-198
FAILURE CODE [B@BAZG] Eng Oil Press Low ...........................................................................40-199
FAILURE CODE [B@BAZK] Eng Oil Level Low ............................................................................40-200
FAILURE CODE [B@BCNS] Eng Water Overheat ........................................................................40-202
FAILURE CODE [B@BCZK] Eng Water Level Low .......................................................................40-203
FAILURE CODE [B@HANS] Hyd Oil Overheat .............................................................................40-205
FAILURE CODE [CA115] Engine NE and Backup Speed Sensor Error.........................................40-206
FAILURE CODE [CA122] Charge Air Pressure Sensor High Error................................................40-207
FAILURE CODE [CA123] Charge Air Pressure Sensor Low Error.................................................40-209

PC490LC-11 00-5
INDEX 00 INDEX AND FOREWORD

FAILURE CODE [CA131] Throttle Sensor High Error....................................................................40-211

FAILURE CODE [CA132] Throttle Sensor Low Error.....................................................................40-213
FAILURE CODE [CA135] Engine Oil Pressure Sensor High Error ................................................40-215
FAILURE CODE [CA141] Engine Oil Pressure Sensor Low Error .................................................40-217
FAILURE CODE [CA144] Coolant Temperature Sensor High Error...............................................40-219
FAILURE CODE [CA145] Coolant Temperature Sensor Low Error................................................40-221
FAILURE CODE [CA153] Charge Air Temperature Sensor High Error ..........................................40-223
FAILURE CODE [CA154] Charge Air Temperature Sensor Low Error...........................................40-226
FAILURE CODE [CA187] Sensor 2 Supply Voltage Low Error ......................................................40-229
FAILURE CODE [CA221] Ambient Pressure Sensor High Error....................................................40-231
FAILURE CODE [CA222] Ambient Pressure Sensor Low Error ....................................................40-233
FAILURE CODE [CA227] Sensor 2 Supply Voltage High Error .....................................................40-235
FAILURE CODE [CA234] Engine Overspeed................................................................................40-236
FAILURE CODE [CA238] NE Speed Sensor Supply Voltage Error ...............................................40-237
FAILURE CODE [CA239] NE Speed Sensor Supply Voltage High Error .......................................40-239
FAILURE CODE [CA249] Ambient Air Temp Sensor High Error ....................................................40-241
FAILURE CODE [CA256] Ambient Air Temp Sensor Low Error.....................................................40-243
FAILURE CODE [CA271] IMV/PCV 1 Short Circuit Error ..............................................................40-245
FAILURE CODE [CA272] IMV/PCV 1 Open Circuit Error ..............................................................40-247
FAILURE CODE [CA273] PCV 2 Short Circuit Error......................................................................40-248
FAILURE CODE [CA274] PCV 2 Open Circuit Error .....................................................................40-250
FAILURE CODE [CA322] Injector #1 (L#1) Open Circuit Error or Short Circuit Error ....................40-251
FAILURE CODE [CA323] Injector #5 (L#5) Open Circuit Error or Short Circuit Error ....................40-253
FAILURE CODE [CA324] Injector #3 (L#3) Open Circuit Error or Short Circuit Error ....................40-255
FAILURE CODE [CA325] Injector #6 (L#6) Open Circuit Error or Short Circuit Error ....................40-257
FAILURE CODE [CA331] Injector #2 (L#2) Open Circuit Error or Short Circuit Error ....................40-259
FAILURE CODE [CA332] Injector #4 (L#4) Open Circuit Error or Short Circuit Error ....................40-261
FAILURE CODE [CA343] Engine Controller Internal Failure .........................................................40-263
FAILURE CODE [CA351] Injectors Drive Circuit Error...................................................................40-264
FAILURE CODE [CA352] Sensor 1 Supply Voltage Low Error ......................................................40-265
FAILURE CODE [CA356] MAF Sensor High Error ........................................................................40-268
FAILURE CODE [CA357] MAF Sensor Low Error .........................................................................40-270
FAILURE CODE [CA386] Sensor 1 Supply Voltage High Error .....................................................40-272
FAILURE CODE [CA441] Battery Voltage Low Error.....................................................................40-273
FAILURE CODE [CA442] Battery Voltage High Error ....................................................................40-275
FAILURE CODE [CA449] Common Rail Pressure High Error 2 ....................................................40-276
FAILURE CODE [CA451] Common Rail Pressure Sensor High Error ...........................................40-277
FAILURE CODE [CA452] Common Rail Pressure Sensor Low Error ............................................40-279
FAILURE CODE [CA515] Common Rail Pressure Sensor Supply Voltage High Error...................40-281
FAILURE CODE [CA516] Common Rail Pressure Sensor Supply Voltage Low Error....................40-283
FAILURE CODE [CA553] Common Rail Pressure High Error 1 ....................................................40-285
FAILURE CODE [CA555] Crankcase Pressure High Error 1 .........................................................40-286
FAILURE CODE [CA556] Crankcase Pressure High Error 2 .........................................................40-287
FAILURE CODE [CA559] Common Rail Pressure Low Error 1 .....................................................40-288
FAILURE CODE [CA595] Turbocharger Speed High Error 2.........................................................40-293
FAILURE CODE [CA687] Turbocharger Speed Low Error ............................................................40-294
FAILURE CODE [CA689] Engine NE Speed Sensor Error ............................................................40-296
FAILURE CODE [CA691] Intake Air Temperature Sensor High Error ............................................40-298
FAILURE CODE [CA692] Intake Air Temperature Sensor Low Error.............................................40-300
FAILURE CODE [CA697] Engine Controller Internal Temperature Sensor High Error ...................40-302
FAILURE CODE [CA698] Engine Controller Internal Temperature Sensor Low Error....................40-303
FAILURE CODE [CA731] Engine Backup Speed Sensor Phase Error ..........................................40-304
FAILURE CODE [CA778] Engine Backup Speed Sensor Error .....................................................40-305
FAILURE CODE [CA1117] Engine Controller Partial Data Lost Error ............................................40-308
FAILURE CODE [CA1664] KDOC Abnormality .............................................................................40-309
FAILURE CODE [CA1669] AdBlue/DEF Level Sensor Voltage High Error ....................................40-312
FAILURE CODE [CA1673] AdBlue/DEF Level Low Error 3 ...........................................................40-313
FAILURE CODE [CA1677] AdBlue/DEF Temperature Sensor Low Error .....................................40-314

00-6 PC490LC-11
00 INDEX AND FOREWORD INDEX

FAILURE CODE [CA1678] AdBlue/DEF Temperature Sensor High Error .....................................40-315

FAILURE CODE [CA1682] AdBlue/DEF Pump Priming Error........................................................40-316
FAILURE CODE [CA1683] AdBlue/DEF Tank Heating Valve Voltage High Error...........................40-318
FAILURE CODE [CA1684] AdBlue/DEF Tank Heating Valve Voltage Low Error ...........................40-320
FAILURE CODE [CA1686] AdBlue/DEF Quality Sensor Voltage High Error..................................40-322
FAILURE CODE [CA1691] Defective Regeneration ......................................................................40-323
FAILURE CODE [CA1694] SCR Outlet NOx Sensor In Range Error.............................................40-326
FAILURE CODE [CA1695] Sensor 5 Supply Voltage High Error ...................................................40-329
FAILURE CODE [CA1696] Sensor 5 Supply Voltage Low Error ....................................................40-330
FAILURE CODE [CA1712] AdBlue/DEF Tank Thawing Error .......................................................40-332
FAILURE CODE [CA1713] AdBlue/DEF Tank Heater Valve Open Stuck Error..............................40-335
FAILURE CODE [CA1714] AdBlue/DEF Quality Sensor Out of Calibration Error ..........................40-337
FAILURE CODE [CA1715] AdBlue/DEF Quality Sensor Internal Circuit Error ...............................40-338
FAILURE CODE [CA1776] Sensor Supply Relay Voltage High Error ............................................40-339
FAILURE CODE [CA1777] Sensor Supply Relay Voltage Low Error .............................................40-342
FAILURE CODE [CA1843] Crankcase Pressure Sensor High Error..............................................40-345
FAILURE CODE [CA1844] Crankcase Pressure Sensor Low Error...............................................40-347
FAILURE CODE [CA1879] KDPF Differential Pressure Sensor High Error ...................................40-350
FAILURE CODE [CA1881] KDPF Differential Pressure Sensor Low Error ....................................40-353
FAILURE CODE [CA1883] KDPF Differential Pressure Sensor In Range Error ............................40-355
FAILURE CODE [CA1885] Turbo Outlet NOx Sensor Circuit Error ...............................................40-358
FAILURE CODE [CA1887] SCR Outlet NOx Sensor Circuit Error .................................................40-360
FAILURE CODE [CA1921] KDPF Soot Accumulation High Error 1 ...............................................40-362
FAILURE CODE [CA1922] KDPF Soot Accumulation High Error 2 ...............................................40-365
FAILURE CODE [CA1923] Fuel Doser Solenoid 1 High Error .......................................................40-370
FAILURE CODE [CA1924] Fuel Doser Solenoid 1 Low Error........................................................40-372
FAILURE CODE [CA1925] Fuel Doser Solenoid 1 In Range Error ................................................40-374
FAILURE CODE [CA1927] Dosing Fuel Pressure Sensor High Error............................................40-376
FAILURE CODE [CA1928] Dosing Fuel Pressure Sensor Low Error.............................................40-378
FAILURE CODE [CA1942] Crankcase Pressure Sensor In Range Error.......................................40-380
FAILURE CODE [CA1963] Fuel Doser Solenoid 1 Servo Error .....................................................40-381
FAILURE CODE [CA1977] Fuel Doser Open Error or Short Error .................................................40-384
FAILURE CODE [CA1993] KDPF Differential Pressure Low Error ................................................40-387
FAILURE CODE [CA2185] Throttle Sensor Supply Voltage High Error .........................................40-390
FAILURE CODE [CA2186] Throttle Sensor Supply Voltage Low Error ..........................................40-392
FAILURE CODE [CA2249] Common Rail Pressure Low Error 2 ...................................................40-394
FAILURE CODE [CA2265] Fuel Feed Pump Open Error ..............................................................40-395
FAILURE CODE [CA2266] Fuel Feed Pump Short Error...............................................................40-397
FAILURE CODE [CA2271] EGR Valve Position Sensor High Error ...............................................40-399
FAILURE CODE [CA2272] EGR Valve Position Sensor Low Error................................................40-401
FAILURE CODE [CA2349] EGR Valve Solenoid Open Circuit Error..............................................40-403
FAILURE CODE [CA2353] EGR Valve Solenoid Short Circuit Error ..............................................40-405
FAILURE CODE [CA2357] EGR Valve Servo Error.......................................................................40-407
FAILURE CODE [CA2381] KVGT Position Sensor High Error.......................................................40-408
FAILURE CODE [CA2382] KVGT Position Sensor Low Error .......................................................40-410
FAILURE CODE [CA2383] KVGT Solenoid Open Circuit Error .....................................................40-412
FAILURE CODE [CA2386] KVGT Solenoid Short Circuit Error .....................................................40-414
FAILURE CODE [CA2387] KVGT Servo Error ..............................................................................40-416
FAILURE CODE [CA2555] Intake Air Heater Relay Open Circuit Error .........................................40-417
FAILURE CODE [CA2556] Intake Air Heater Relay Short Circuit Error .........................................40-420
FAILURE CODE [CA2637] KDOC Face Plugging .........................................................................40-422
FAILURE CODE [CA2639] Manual Stationary Regeneration Request ..........................................40-424
FAILURE CODE [CA2732] Fuel Doser Solenoid 2 High Error .......................................................40-427
FAILURE CODE [CA2733] Fuel Doser Solenoid 2 Low Error........................................................40-429
FAILURE CODE [CA2741] Fuel Dozer Solenoid Valve Swap Error...............................................40-431
FAILURE CODE [CA2765] Injector Trim Data Mismatch ...............................................................40-432
FAILURE CODE [CA2771] SCR Outlet NOx Sensor Datalink Timeout Error.................................40-433

PC490LC-11 00-7
INDEX 00 INDEX AND FOREWORD

FAILURE CODE [CA2777] Manual Stationary Regeneration Request but KDPF Regeneration Disable ..
..................................................................................................................................................40-439
FAILURE CODE [CA2878] Fuel Doser Solenoid 2 Servo Error .....................................................40-442
FAILURE CODE [CA2881] Dosing Fuel Pressure Low Error 1......................................................40-445
FAILURE CODE [CA2976] AdBlue/DEF Pump Temperature Sensor Signal Error.........................40-448
FAILURE CODE [CA3133] KDPF Outlet Pressure Sensor High Error...........................................40-450
FAILURE CODE [CA3134] KDPF Outlet Pressure Sensor Low Error............................................40-452
FAILURE CODE [CA3135] KDPF Outlet Pressure Sensor In Range Error....................................40-454
FAILURE CODE [CA3142] SCR Temperature Sensor High Error..................................................40-457
FAILURE CODE [CA3143] SCR Temperature Sensor Low Error ..................................................40-458
FAILURE CODE [CA3144] SCR Temperature Sensor In Range Error ..........................................40-459
FAILURE CODE [CA3146] SCR Outlet Temperature Sensor High Error .......................................40-461
FAILURE CODE [CA3147] SCR Outlet Temperature Sensor Low Error ........................................40-462
FAILURE CODE [CA3148] SCR Outlet Temperature Sensor In Range Error ................................40-463
FAILURE CODE [CA3151] SCR Catalyst Efficiency Low Error 2...................................................40-465
FAILURE CODE [CA3165] SCR Outlet Temperature High Error ...................................................40-471
FAILURE CODE [CA3167] Fuel Doser Degradation......................................................................40-473
FAILURE CODE [CA3229] SCR Temperature High Error..............................................................40-476
FAILURE CODE [CA3231] SCR Temperature High Error - Non Regeneration ..............................40-478
FAILURE CODE [CA3232] Turbo Outlet NOx Sensor Datalink Timeout Error ...............................40-480
FAILURE CODE [CA3235] SCR Outlet Temperature High Error - Non Regeneration....................40-484
FAILURE CODE [CA3239] AdBlue/DEF Line Heater 2 Voltage High Error....................................40-486
FAILURE CODE [CA3241] AdBlue/DEF Line Heater 2 Voltage Low Error ....................................40-489
FAILURE CODE [CA3242] AdBlue/DEF Tank Heating Error .........................................................40-492
FAILURE CODE [CA3251] KDOC Inlet Temperature High Error ...................................................40-495
FAILURE CODE [CA3253] KDOC Temperature Error - Non Regeneration ...................................40-497
FAILURE CODE [CA3254] KDOC Outlet Temperature High Error 1..............................................40-500
FAILURE CODE [CA3255] KDPF Temperature Error - Non Regeneration ....................................40-503
FAILURE CODE [CA3256] KDPF Outlet Temperature High Error 1 ..............................................40-506
FAILURE CODE [CA3311] KDOC Outlet Temperature High Error 2 ..............................................40-508
FAILURE CODE [CA3312] KDPF Outlet Temperature High Error 2 ..............................................40-510
FAILURE CODE [CA3313] KDOC Inlet Temperature Sensor Low Error ........................................40-513
FAILURE CODE [CA3314] KDOC Inlet Temperature Sensor High Error .......................................40-515
FAILURE CODE [CA3315] KDOC Inlet Temperature Sensor In Range Error ................................40-516
FAILURE CODE [CA3316] KDOC Outlet Temperature Sensor Low Error .....................................40-519
FAILURE CODE [CA3317] KDOC Outlet Temperature Sensor High Error ....................................40-520
FAILURE CODE [CA3318] KDOC Outlet Temperature Sensor In Range Error .............................40-521
FAILURE CODE [CA3319] KDPF Outlet Temperature Sensor High Error .....................................40-523
FAILURE CODE [CA3321] KDPF Outlet Temperature Sensor Low Error ......................................40-524
FAILURE CODE [CA3322] KDPF Outlet Temperature Sensor In Range Error ..............................40-526
FAILURE CODE [CA3419] MAF Sensor Supply Voltage High Error..............................................40-529
FAILURE CODE [CA3421] MAF Sensor Supply Voltage Low Error...............................................40-531
FAILURE CODE [CA3497] AdBlue/DEF Level Low Error 1 ...........................................................40-533
FAILURE CODE [CA3498] AdBlue/DEF Level Low Error 2 ...........................................................40-534
FAILURE CODE [CA3543] AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low)...................40-535
FAILURE CODE [CA3545] SCR Outlet NOx Sensor Unstable Error .............................................40-541
FAILURE CODE [CA3547] AdBlue/DEF Level Low Error 4 ...........................................................40-543
FAILURE CODE [CA3558] AdBlue/DEF Pump Voltage High Error................................................40-544
FAILURE CODE [CA3559] AdBlue/DEF Pump Voltage Low Error ................................................40-546
FAILURE CODE [CA3562] AdBlue/DEF LineHeater Relay 1 Voltage High Error...........................40-548
FAILURE CODE [CA3563] AdBlue/DEF LineHeater Relay 1 Voltage Low Error ...........................40-550
FAILURE CODE [CA3567] AdBlue/DEF Injector Open Circuit Error or Short Circuit Error ............40-553
FAILURE CODE [CA3568] AdBlue/DEF Injector Malfunction ........................................................40-556
FAILURE CODE [CA3571] AdBlue/DEF Pump Pressure Sensor High Error .................................40-560
FAILURE CODE [CA3572] AdBlue/DEF Pump Pressure Sensor Low Error..................................40-562
FAILURE CODE [CA3574] AdBlue/DEF Pump Pressure Too Low Error .......................................40-564
FAILURE CODE [CA3575] AdBlue/DEF Pump Pressure Too High Error.......................................40-566
FAILURE CODE [CA3577] AdBlue/DEF FCV Voltage High Error..................................................40-568

00-8 PC490LC-11
00 INDEX AND FOREWORD INDEX

FAILURE CODE [CA3578] AdBlue/DEF FCV Voltage Low Error ..................................................40-570

FAILURE CODE [CA3582] SCR Catalyst Efficiency Low Error 1...................................................40-572
FAILURE CODE [CA3583] SCR Outlet NOx Sensor Heater Warming up Error.............................40-578
FAILURE CODE [CA3596] AdBlue/DEF Pump Pressure Unstable Error.......................................40-580
FAILURE CODE [CA3649] Turbo Outlet NOx Sensor Heater Warming up Error ...........................40-582
FAILURE CODE [CA3681] SCR Outlet NOx Sensor Power Voltage Error ....................................40-584
FAILURE CODE [CA3682] Turbo Outlet NOx Sensor Power Voltage Error...................................40-589
FAILURE CODE [CA3713] AdBlue/DEF Line Heater 1 Voltage High Error....................................40-595
FAILURE CODE [CA3717] SCR Outlet NOx Sensor Voltage Mismatch Error ...............................40-598
FAILURE CODE [CA3718] Turbo Outlet NOx Sensor Voltage Mismatch Error..............................40-599
FAILURE CODE [CA3725] Turbo Outlet NOx Sensor Unstable Error............................................40-600
FAILURE CODE [CA3748] Turbo Outlet NOx Sensor Stuck In Range Error .................................40-603
FAILURE CODE [CA3751] SCR Catalyst Degradation Error.........................................................40-605
FAILURE CODE [CA3755] AdBlue/DEF Dosing Performance Degradation Error .........................40-607
FAILURE CODE [CA3866] AdBlue/DEF Low Concentration Error 2 .............................................40-609
FAILURE CODE [CA3867] AdBlue/DEF Low Concentration Error 1 .............................................40-612
FAILURE CODE [CA3868] AdBlue/DEF Tank Sensor Datalink Timeout Error...............................40-615
FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Error............................................................40-619
FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error ...........................................40-621
FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warming up Error .......................................40-625
FAILURE CODE [CA3932] SCR NH3 Sensor Heater Voltage High Error ......................................40-627
FAILURE CODE [CA3933] SCR NH3 Sensor Heater Voltage Low Error.......................................40-629
FAILURE CODE [CA3934] SCR NH3 Sensor Power Interrupt Error .............................................40-631
FAILURE CODE [CA3935] SCR NH3 Sensor Trim Resistance Error ............................................40-634
FAILURE CODE [CA3936] SCR NH3 Sensor Internal Circuit Error...............................................40-636
FAILURE CODE [CA4151] KDOC and KDPF Temperature Sensor Datalink Timeout Error ..........40-638
FAILURE CODE [CA4152] SCR Temperature Sensor Datalink Timeout Error ..............................40-643
FAILURE CODE [CA4155] AdBlue/DEF Pump Heater Relay Voltage High Error ..........................40-647
FAILURE CODE [CA4156] AdBlue/DEF Pump Heater Relay Voltage Low Error...........................40-650
FAILURE CODE [CA4157] AdBlue/DEF FCV Malfunction ............................................................40-653
FAILURE CODE [CA4158] KDOC and KDPF Temperature Sensor Internal Circuit Error ..............40-655
FAILURE CODE [CA4159] SCR Temperature Sensor Internal Circuit Error ..................................40-656
FAILURE CODE [CA4161] KDOC and KDPF Temperature Sensor ECU Voltage High Error ........40-657
FAILURE CODE [CA4162] KDOC and KDPF Temperature Sensor ECU Voltage Low Error .........40-660
FAILURE CODE [CA4163] KDOC and KDPF Temperature Sensor ECU Over Temperature Error 40-663
FAILURE CODE [CA4164] SCR Temperature Sensor ECU Voltage High Error ............................40-666
FAILURE CODE [CA4165] SCR Temperature Sensor ECU Voltage Low Error .............................40-668
FAILURE CODE [CA4166] SCR Temperature Sensor ECU High Temperature Error ....................40-670
FAILURE CODE [CA4168] AdBlue/DEF Pump Heater ON Stuck Error .........................................40-672
FAILURE CODE [CA4169] AdBlue/DEF Pump Heater OFF Stuck Error .......................................40-675
FAILURE CODE [CA4171] AdBlue/DEF Pump Thawing Error ......................................................40-677
FAILURE CODE [CA4249] AdBlue/DEF Pump Temperature Sensor 1 In Range Error .................40-680
FAILURE CODE [CA4251] AdBlue/DEF Pump Temperature Sensor 2 In Range Error .................40-682
FAILURE CODE [CA4259] KDOC and KDPF Temperature Sensor Power Interrupt Error.............40-684
FAILURE CODE [CA4261] SCR Temperature Sensor Power Interrupt Error.................................40-686
FAILURE CODE [CA4277] AdBlue/DEF Quality Sensor Liquid Distinction Impossible Error .........40-689
FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Response Error............................................40-692
FAILURE CODE [CA4459] AdBlue/DEF LineHeater Relay 2 Voltage High Error...........................40-695
FAILURE CODE [CA4461] AdBlue/DEF LineHeater Relay 2 Voltage Low Error ...........................40-698
FAILURE CODE [CA4658] AdBlue/DEF Flow Low Error...............................................................40-701
FAILURE CODE [CA4731] AdBlue/DEF Temperature Sensor Transmission Data Error................40-705
FAILURE CODE [CA4732] AdBlue/DEF Level Sensor Transmission Data Error ...........................40-706
FAILURE CODE [CA4739] AdBlue/DEF Level Sensor Internal Circuit Error .................................40-707
FAILURE CODE [CA4768] Fuel in AdBlue/DEF Tank Error...........................................................40-708
FAILURE CODE [CA4769] AdBlue/DEF Level Measurement Impossible......................................40-710
FAILURE CODE [CA4842] AdBlue/DEF High Concentration Error................................................40-713
FAILURE CODE [CA4952] System Operating Lamp Short Circuit (Engine Controller) ..................40-716
FAILURE CODE [CA5115] AdBlue/DEF Line Heater 1 Voltage Low Error.....................................40-718

PC490LC-11 00-9
INDEX 00 INDEX AND FOREWORD

FAILURE CODE [CA5179] Engine Room Temperature Sensor High Error....................................40-721

FAILURE CODE [CA5181] Engine Room Temperature Sensor Low Error ....................................40-723
FAILURE CODE [CA5383] Ash Accumulation High Error..............................................................40-725
FAILURE CODE [D110KB] Battery Relay Output Short Circuit......................................................40-727
FAILURE CODE [D19JKZ] Personal Code Relay Open Circuit or Short Circuit.............................40-729
FAILURE CODE [D811MC] KOMTRAX Malfunction......................................................................40-732
FAILURE CODE [D862KA] GPS Antenna Open Circuit ................................................................40-733
FAILURE CODE [D8ALKA] System Operating Lamp Open Circuit (KOMTRAX)...........................40-734
FAILURE CODE [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) ...........................40-736
FAILURE CODE [D8AQKR] CAN 2 Defective Communication (KOMTRAX) .................................40-738
FAILURE CODE [DA20MC] Pump Controller Malfunction .............................................................40-740
FAILURE CODE [DA22KK] Pump Controller Solenoid Power Voltage Low Error ..........................40-741
FAILURE CODE [DA25KP] 5V Sensor 1 Power Voltage Low Error...............................................40-744
FAILURE CODE [DA29KQ] Model Selection Signal Mismatch (Pump Controller) .........................40-747
FAILURE CODE [DA2LKA] System Operating Lamp Open Circuit (Pump Controller)...................40-749
FAILURE CODE [DA2LKB] System Operating Lamp Short Circuit (Pump Controller) ...................40-751
FAILURE CODE [DA2QKR] Controller Area Network 2 Defective Communication (Pump Controller)......
..................................................................................................................................................40-753
FAILURE CODE [DA2RKR] Controller Area Network 1 Defective Communication (Pump Controller)......
..................................................................................................................................................40-756
FAILURE CODE [DAF0MB] Monitor ROM Abnormality.................................................................40-757
FAILURE CODE [DAF0MC] Monitor Malfunction ..........................................................................40-758
FAILURE CODE [DAF8KB] Camera Power Supply Short Circuit ..................................................40-759
FAILURE CODE [DAF9KQ] Model Selection Signal Mismatch (Monitor).......................................40-761
FAILURE CODE [DAFGMC] GPS Module Malfunction .................................................................40-762
FAILURE CODE [DAFLKA] System Operating Lamp Open Circuit (Monitor) ................................40-763
FAILURE CODE [DAFLKB] System Operating Lamp Short Circuit (Monitor) ................................40-765
FAILURE CODE [DAFQKR] CAN 2 Defective Communication (Monitor) ......................................40-767
FAILURE CODE [DAZ9KQ] Model Selection Signal Mismatch (A/C) ............................................40-768
FAILURE CODE [DAZQKR] CAN 2 Defective Communication (A/C ECU)....................................40-769
FAILURE CODE [DB2QKR] CAN 2 Defective Communication (Engine Controller) .......................40-774
FAILURE CODE [DB2RKR] CAN 1 Defective Communication (Engine Controller) .......................40-779
FAILURE CODE [DDNRKA] W/E Lever Lock SW Open Circuit.....................................................40-783
FAILURE CODE [DDNRKY] W/E Lever Lock SW Short Circuit .....................................................40-785
FAILURE CODE [DDNS00] Lock Lever Auto Lock Release SW On..............................................40-787
FAILURE CODE [DGH2KA] Hydraulic Oil Temperature Sensor Open Circuit................................40-789
FAILURE CODE [DGH2KB] Hydraulic Oil Temperature Sensor Ground Fault...............................40-791
FAILURE CODE [DHA4KA] Air Cleaner Clog Sensor Open Circuit ...............................................40-793
FAILURE CODE [DHAAMA] KDPF Differential Pressure Sensor Frozen ......................................40-795
FAILURE CODE [DHACMA] KDPF Outlet Pressure Sensor Frozen .............................................40-796
FAILURE CODE [DHPAMA] Front Pump Pressure Sensor Defective Function .............................40-797
FAILURE CODE [DHPBMA] Rear Pump Pressure Sensor Defective Function .............................40-800
FAILURE CODE [DHS3MA] Arm IN PPC Pressure Sensor Defective Function ............................40-803
FAILURE CODE [DHS4MA] Bucket CURL PPC Pressure Sensor Defective Function ..................40-806
FAILURE CODE [DHS8MA] Boom RAISE PPC Pressure Sensor Defective Function...................40-809
FAILURE CODE [DHS9MA] Boom LOWER PPC Pressure Sensor Defective Function ................40-812
FAILURE CODE [DHSAMA] Swing Right PPC Pressure Sensor Defective Function ....................40-815
FAILURE CODE [DHSBMA] Swing Left PPC Pressure Sensor Defective Function ......................40-818
FAILURE CODE [DHSCMA] Arm OUT PPC Pressure Sensor Defective Function........................40-821
FAILURE CODE [DHSDMA] Bucket DUMP PPC Pressure Sensor Defective Function.................40-824
FAILURE CODE [DHSFMA] Travel Forward Left PPC Pressure Sensor Defective Function.........40-827
FAILURE CODE [DHSGMA] Travel Forward Right PPC Pressure Sensor Defective Function......40-830
FAILURE CODE [DHSHMA] Travel Reverse Left PPC Pressure Sensor Defective Function ........40-833
FAILURE CODE [DHSJMA] Travel Reverse Right PPC Pressure Sensor Defective Function.......40-836
FAILURE CODE [DKR0MA] Front Pump Swash Plate Sensor Defective Function........................40-839
FAILURE CODE [DKR1MA] Rear Pump Swash Plate Sensor Defective Function ........................40-842
FAILURE CODE [DKULKA] PPC Lock Relay Open Circuit ...........................................................40-845
FAILURE CODE [DKULKB] PPC Lock Relay Short Circuit............................................................40-847

00-10 PC490LC-11
00 INDEX AND FOREWORD INDEX

FAILURE CODE [DKULKY] PPC Lock Relay Hot Short Circuit .....................................................40-849
FAILURE CODE [DLM3KA] Fan Speed Sensor Open Circuit........................................................40-850
FAILURE CODE [DLM3KB] Fan Speed Sensor Short Circuit........................................................40-852
FAILURE CODE [DLM3MB] Fan control:Mismatch .......................................................................40-854
FAILURE CODE [DR21KX] Camera 2 Picture Reverse Drive Input Out of Range ........................40-855
FAILURE CODE [DR31KX] Camera 3 Picture Reverse Drive Input Out of Range ........................40-857
FAILURE CODE [DV20KB] Travel Alarm Short Circuit ..................................................................40-859
FAILURE CODE [DW43KA] Travel Speed Solenoid Open Circuit .................................................40-861
FAILURE CODE [DW43KB] Travel Speed Solenoid Short Circuit .................................................40-863
FAILURE CODE [DW43KY] Travel Speed Solenoid Hot Short Circuit...........................................40-865
FAILURE CODE [DW45KA]Swing Parking Brake Solenoid Open Circuit ......................................40-867
FAILURE CODE [DW45KB] Swing Parking Brake Solenoid Short Circuit .....................................40-870
FAILURE CODE [DW45KY] Swing Parking Brake Solenoid Hot Short Circuit ...............................40-873
FAILURE CODE [DW4CKY] PPC Lock Solenoid Hot Short Circuit ...............................................40-875
FAILURE CODE [DW7BKA] Fan Reverse Solenoid Open Circuit .................................................40-876
FAILURE CODE [DW7BKB] Fan Reverse Solenoid Short Circuit..................................................40-878
FAILURE CODE [DW7BKY] Fan Reverse Solenoid Hot Short Circuit ...........................................40-880
FAILURE CODE [DW91KA] Travel Junction Solenoid Open Circuit ..............................................40-881
FAILURE CODE [DW91KB] Travel Junction Solenoid Short Circuit ..............................................40-883
FAILURE CODE [DW91KY] Travel Junction Solenoid Hot Short Circuit........................................40-885
FAILURE CODE [DWA2KA] Attachment Single or 2-Way Change Solenoid Open Circuit.............40-887
FAILURE CODE [DWA2KB] Attachment Single or 2-Way Change Solenoid Short Circuit.............40-889
FAILURE CODE [DWA2KY] Attachment Single or 2-Way Change Solenoid Hot Short Circuit ......40-891
FAILURE CODE [DWK0KA] 2-Stage Relief Solenoid Open Circuit ...............................................40-893
FAILURE CODE [DWK0KB] 2-Stage Relief Solenoid Open Circuit ...............................................40-895
FAILURE CODE [DWK0KY] 2-Stage Relief Solenoid Hot Short Circuit .........................................40-897
FAILURE CODE [DWK2KA] Variable Back Pressure Solenoid Open Circuit .................................40-899
FAILURE CODE [DWK2KB] Variable Back Pressure Solenoid Short Circuit .................................40-901
FAILURE CODE [DWK2KY] Variable Back Pressure Solenoid Hot Short Circuit...........................40-903
FAILURE CODE [DWK8KA] Swing Pressure Cutoff Solenoid Open Circuit ..................................40-905
FAILURE CODE [DWK8KB] Swing Pressure Cutoff Solenoid Short Circuit...................................40-907
FAILURE CODE [DWK8KY] Swing Pressure Cutoff Solenoid Hot Short Circuit ............................40-909
FAILURE CODE [DX16KA] Fan Pump EPC Solenoid Open Circuit ..............................................40-911
FAILURE CODE [DX16KB] Fan Pump EPC Solenoid Short Circuit...............................................40-913
FAILURE CODE [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit......................................40-915
FAILURE CODE [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit ......................................40-917
FAILURE CODE [DXA9KA] Rear Pump PC-EPC Solenoid Open Circuit ......................................40-919
FAILURE CODE [DXA9KB] Rear Pump PC-EPC Solenoid Short Circuit.......................................40-921
FAILURE CODE [DXE0KA] LS-EPC Solenoid Open Circuit..........................................................40-923
FAILURE CODE [DXE0KB] LS-EPC Solenoid Short Circuit ..........................................................40-925
FAILURE CODE [DXE4KA] Attachment Flow Regulating EPC Solenoid Open Circuit ..................40-927
FAILURE CODE [DXE4KB] Attachment Flow Regulating EPC Solenoid Short Circuit ..................40-929
FAILURE CODE [DXE4KY] Attachment Flow EPC Hot Short Circuit ............................................40-931
FAILURE CODE [DXE5KA] Merge-divider Main Solenoid Open Circuit ........................................40-933
FAILURE CODE [DXE5KB] Merge-divider Main Solenoid Short Circuit ........................................40-935
FAILURE CODE [DXE6KA] Merge-divider LS Solenoid Open Circuit............................................40-937
FAILURE CODE [DXE6KB] Merge-divider LS Solenoid Short Circuit............................................40-939
FAILURE CODE [DXE7KA] Attachment Flow Regulating EPC 2 Solenoid Open Circuit ...............40-941
FAILURE CODE [DXE7KB] Attachment Flow Regulating EPC 2 Solenoid Short Circuit ...............40-943
FAILURE CODE [DXE7KY] Attachment Flow Regulating EPC 2 Hot Short Circuit........................40-945
FAILURE CODE [DXE8KA] Attachment Flow Regulating EPC 3 Solenoid Open Circuit ...............40-947
FAILURE CODE [DXE8KB] Attachment Flow Regulating EPC 3 Solenoid Short Circuit ...............40-949
FAILURE CODE [DXE8KY] Attachment Flow Regulating EPC 3 Hot Short Circuit........................40-951
FAILURE CODE [DXE9KA] Attachment Flow Regulating EPC 4 Solenoid Open Circuit ...............40-953
FAILURE CODE [DXE9KB] Attachment Flow Regulating EPC 4 Solenoid Short Circuit ...............40-955
FAILURE CODE [DXE9KY] Attachment Flow Regulating EPC 4 Hot Short Circuit........................40-957
FAILURE CODE [DXEAKA] Attachment Flow Regulating EPC 5 Solenoid Open Circuit...............40-959
FAILURE CODE [DXEAKB] Attachment Flow Regulating EPC 5 Solenoid Short Circuit ...............40-961

PC490LC-11 00-11
INDEX 00 INDEX AND FOREWORD

FAILURE CODE [DXEAKY] Attachment Flow Regulating EPC 1 Hot Short Circuit .......................40-963
FAILURE CODE [DY20KA]Wiper Motor Open Circuit ...................................................................40-965
FAILURE CODE [DY20MA] Wiper Motor Defective Function ........................................................40-967
FAILURE CODE [DY2CKB] Washer Motor Short Circuit ...............................................................40-969
FAILURE CODE [DY2DKB] Wiper Motor (Normal Rotation) Short Circuit .....................................40-972
FAILURE CODE [DY2EKB] Wiper Motor (Reverse Rotation) Short Circuit....................................40-974
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ...........................................................40-976
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) ................................................40-976
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK..........................................................40-982
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK ....................................................40-985
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP.......40-987
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS
NOTHING..................................................................................................................................40-989
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), EN-
GINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW .............................................................40-992
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIA-
TOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW ...................................................40-993
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUN-
NING .........................................................................................................................................40-994
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUN-
NING .........................................................................................................................................40-995
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING...
..................................................................................................................................................40-996
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING................40-997
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING......................40-998
E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-
NING .........................................................................................................................................40-999
E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-1000
E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-
NING .......................................................................................................................................40-1001
E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .................40-1002
E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL...............................40-1004
E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM
OR MAXIMUM.........................................................................................................................40-1005
E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOL-
ANT TEMPERATURE..............................................................................................................40-1006
E-20 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR
MAXIMUM ...............................................................................................................................40-1007
E-21 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEM-
PERATURE .............................................................................................................................40-1009
E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED ......................40-1010
E-23 FUNCTION SWITCH DOES NOT OPERATE .....................................................................40-1011
E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)..................40-1012
E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR
DOES NOT LIGHT UP OR DOES NOT GO OFF ....................................................................40-1013
E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER ....................40-1014
E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS
NOT DISPLAYED ....................................................................................................................40-1015
E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS
NOT CHANGED ......................................................................................................................40-1016
E-29 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT
CHANGE .................................................................................................................................40-1017
E-30 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT
CHANGE .................................................................................................................................40-1018
E-31 ALARM BUZZER CANNOT BE CANCELED ......................................................................40-1020
E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION.........
................................................................................................................................................40-1021
E-33 SERVICE MODE CANNOT BE SELECTED .......................................................................40-1022

00-12 PC490LC-11
00 INDEX AND FOREWORD INDEX

E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE ....40-1023
E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK........40-1025
E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT
SWING ....................................................................................................................................40-1026
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING
BRAKE DOES NOT OPERATE ...............................................................................................40-1029
E-38 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDI-
CATOR NOT DISPLAYED ON MONITOR ...............................................................................40-1031
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED ...........................40-1034
E-40 ALARM DOES NOT SOUND DURING TRAVEL ................................................................40-1035
E-41 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED..........................40-1037
E-42 HORN DOES NOT SOUND................................................................................................40-1038
E-43 HORN DOES NOT STOP SOUNDING...............................................................................40-1042
E-44 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .
................................................................................................................................................40-1044
E-45 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE...40-1045
E-46 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPER-
ATE .........................................................................................................................................40-1047
E-47 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ...
................................................................................................................................................40-1048
E-48 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .
................................................................................................................................................40-1049
E-49 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION..........
................................................................................................................................................40-1050
E-50 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 40-1051
E-51 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
................................................................................................................................................40-1052
E-52 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .
................................................................................................................................................40-1053
E-53 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.40-1054
E-54 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION40-1055
E-55 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ..........
................................................................................................................................................40-1056
E-56 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED.......................................40-1058
E-57 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .................................................40-1059
E-58 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED .............................................40-1060
E-59 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE..................................................40-1062
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .....................40-1063
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)...............................40-1063
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS ..........................................40-1064
FAILURE MODE AND CAUSE TABLE........................................................................................40-1066
H-1 All of work equipments, swing and travel operation lack speed or power. .............................40-1074
H-2 Engine speed lowers significantly or engine stalls ................................................................40-1076
H-3 Any of work equipment, swing and travel does not work.......................................................40-1078
H-4 Unusual sound is heard from around hydraulic pump ...........................................................40-1079
H-5 Fine control performance or response is poor ......................................................................40-1080
H-6 Speed or power of boom is low ............................................................................................40-1081
H-7 Speed or power of arm is low ...............................................................................................40-1086
H-8 Speed or power of bucket is low...........................................................................................40-1090
H-9 Work equipment does not move in single operation .............................................................40-1093
H-10 Hydraulic drift of boom is large ...........................................................................................40-1094
H-11 Hydraulic drift of arm is large ..............................................................................................40-1096
H-12 Hydraulic drift of bucket is large..........................................................................................40-1098
H-13 Other work equipment moves when one of work equipment is relieved ..............................40-1099
H-14 In combined operation of work equipment , equipment having heavier load moves slower. 40-1100
H-15 Time lag of work equipment is large ...................................................................................40-1101
H-16 Machine does not travel straight .........................................................................................40-1102
H-17 Machine is hard to steer or travel power is low ...................................................................40-1104

PC490LC-11 00-13
INDEX 00 INDEX AND FOREWORD

H-18 Travel speed is low.............................................................................................................40-1107

H-19 One of tracks does not run .................................................................................................40-1109
H-20 Travel speed does not change, or travel speed is too low or high....................................... 40-1110
H-21 Upper structure does not swing in both right and left directions .......................................... 40-1111
H-22 Upper structure does not swing in only one direction.......................................................... 40-1112
H-23 Swing acceleration or swing speed of upper structure is low in both right and left directions40-1113
H-24 Swing acceleration or swing speed is low in only one direction .......................................... 40-1114
H-25 Overrun of upper structure is large in both right and left directions ..................................... 40-1115
H-26 Upper structure overruns excessively when it stops swing in only one direction ................. 40-1116
H-27 Shock is large when upper structure stops swinging .......................................................... 40-1117
H-28 Large unusual noise is heard when upper structure stops swinging ................................... 40-1118
H-29 Swing drift on a slope is large (while swing parking brake is applied) ................................. 40-1119
H-30 Swing drift on a slope is large (while swing parking brake is released) ...............................40-1120
H-31 Travel speed drops largely in combined operation of swing and trave ................................40-1121
H-32 In combined operation of swing and boom RAISE, boom rising speed is low .....................40-1122
H-33 One-touch power maximizing function does not work .........................................................40-1123
H-34 Machine push-up function does not work............................................................................40-1124
H-35 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) ............................40-1125
H-36 UNUSUAL NOISE IS HEARD FROM AROUND FAN .........................................................40-1126
H-37 Attachment circuit cannot be changed................................................................................40-1127
H-38 Oil flow in attachment circuit cannot be controlled ..............................................................40-1128
TROUBLESHOOTING OF ENGINE (S-MODE) .................................................................................40-1129
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)...............................40-1129
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION.......
................................................................................................................................................40-1130
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT .................................................40-1131
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS
BUT DOES NOT START) ........................................................................................................40-1132
S-4 ENGINE STARTABILITY IS POOR.......................................................................................40-1133
S-5 ENGINE DOES NOT PICK UP SMOOTHLY ........................................................................40-1135
S-6 ENGINE STOPS DURING OPERATION ..............................................................................40-1137
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE ........................................................................40-1139
S-8 ENGINE LACKS POWER.....................................................................................................40-1140
S-9 KDPF GETS CLOGGED IN A SHORT TIME ........................................................................40-1142
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE ..................................................................40-1144
S-11 OIL BECOMES CONTAMINATED QUICKLY ......................................................................40-1145
S-12 FUEL CONSUMPTION IS EXCESSIVE .............................................................................40-1146
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) .......
................................................................................................................................................40-1147
S-14 OIL PRESSURE DROPS ...................................................................................................40-1148
S-15 FUEL MIXES INTO ENGINE OIL........................................................................................40-1150
S-16 WATER MIXES INTO ENGINE OIL (MILKY) ......................................................................40-1151
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) ....................................40-1152
S-18 UNUSUAL NOISE IS HEARD.............................................................................................40-1153
S-19 VIBRATION IS EXCESSIVE ...............................................................................................40-1154
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT.................................................................40-1155
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY ................................................40-1156
S-22 ACTIVE REGENERATION TAKES TIME............................................................................40-1158
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION..............................40-1159
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE ...................................................................40-1160
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) ..........................................................40-1162
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES).........................40-1163
50 DISASSEMBLY AND ASSEMBLY............................................................................................................. 50-1
CONTENTS ............................................................................................................................................ 50-2
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .......................................................... 50-6
HOW TO READ THIS MANUAL....................................................................................................... 50-6
COATING MATERIALS LIST............................................................................................................ 50-7
SPECIAL TOOLS LIST .................................................................................................................. 50-12

00-14 PC490LC-11
00 INDEX AND FOREWORD INDEX

SKETCHES OF SPECIAL TOOLS................................................................................................. 50-24

ENGINE AND COOLING SYSTEM....................................................................................................... 50-30
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .................................................................. 50-30
REMOVE AND INSTALL INJECTOR ASSEMBLY ......................................................................... 50-45
REMOVE AND INSTALL FUEL DOSER ASSEMBLY .................................................................... 50-61
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .............................................................. 50-64
REMOVE AND INSTALL EGR VALVE ASSEMBLY........................................................................ 50-87
REMOVE AND INSTALL EGR COOLER ASSEMBLY.................................................................... 50-91
REMOVE AND INSTALL STARTER ASSEMBLY ..........................................................................50-100
REMOVE AND INSTALL ALTERNATOR BELT .............................................................................50-103
REMOVE AND INSTALL RADIATOR ASSEMBLY ........................................................................ 50-111
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY ...............................................50-116
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY................................................................50-120
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY....................................50-126
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY ...............................................50-135
REMOVE AND INSTALL ENGINE FRONT OIL SEAL ..................................................................50-172
REMOVE AND INSTALL ENGINE REAR OIL SEAL.....................................................................50-179
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .................................................................50-189
REMOVE AND INSTALL FUEL TANK ASSEMBLY .......................................................................50-206
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY ............................................................50-214
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY..............................50-224
REMOVE AND INSTALL KDPF ASSEMBLY.................................................................................50-236
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY ............................................................50-245
REMOVE AND INSTALL SCR ASSEMBLY...................................................................................50-257
REMOVE AND INSTALL KDPF, SCR ASSEMBLY........................................................................50-264
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET ......................................................50-274
REMOVE AND INSTALL KCCV ASSEMBLY ................................................................................50-288
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE ..................................................................50-293
REMOVE AND INSTALL AdBlue/DEF INJECTOR........................................................................50-304
REMOVE AND INSTALL AdBlue/DEF PUMP ...............................................................................50-312
REMOVE AND INSTALL AdBlue/DEF HOSE ...............................................................................50-315
REMOVE AND INSTALL AIR CLEANER ASSEMBLY...................................................................50-329
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY ................................50-333
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY ...................................50-340
POWER TRAIN....................................................................................................................................50-343
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY ...............................50-343
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY......................................................50-345
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY.....................50-356
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .........................................50-359
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY ................................................................50-369
UNDERCARRIAGE AND FRAME........................................................................................................50-371
SEPARATION AND CONNECTION OF TRACK ASSEMBLY........................................................50-371
REMOVE AND INSTALL SPROCKET ..........................................................................................50-376
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY...........................................50-378
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .................................................................50-381
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY ..........................................50-388
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY ................................................50-394
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY ............................................50-400
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY ........................................................50-405
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY...........................................................50-410
HYDRAULIC SYSTEM.........................................................................................................................50-413
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY ..................................................50-413
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY ...................................50-417
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY............................................................50-420
REMOVE AND INSTALL MAIN PUMP ASSEMBLY ......................................................................50-431
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .............................................................50-441
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY ..............................................50-452
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY ......................50-459

PC490LC-11 00-15
INDEX 00 INDEX AND FOREWORD

DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY ..........................................50-462

WORK EQUIPMENT............................................................................................................................50-465
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY .........................................................50-465
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY........................50-473
CAB AND ITS ATTACHMENTS ...........................................................................................................50-480
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY ...........................................................50-480
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) ....................................50-493
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY .............................................................50-505
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY.................................................................50-514
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY .................................................50-529
REMOVE AND INSTALL OPERATOR'S SEAT .............................................................................50-540
REMOVE AND INSTALL SEAT BELT ...........................................................................................50-545
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .................................................................50-547
ELECTRICAL SYSTEM .......................................................................................................................50-560
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY ...................................................50-560
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY.......................................................50-563
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY ........................................................50-571
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR ..........................................................50-578
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR ..............................50-580
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR.........................................50-583
REMOVE AND INSTALL SCR TEMPERATURE SENSOR ...........................................................50-586
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY......................................................50-590
60 MAINTENANCE STANDARD.................................................................................................................... 60-1
CONTENTS ............................................................................................................................................ 60-2
ENGINE AND COOLING SYSTEM......................................................................................................... 60-3
MAINTENANCE STANDARD OF ENGINE MOUNT ........................................................................ 60-3
MAINTENANCE STANDARD OF COOLING SYSTEM .................................................................... 60-4
MAINTENANCE STANDARD OF COOLING FAN PUMP................................................................. 60-5
MAINTENANCE STANDARD OF COOLING FAN MOTOR.............................................................. 60-7
POWER TRAIN....................................................................................................................................... 60-8
MAINTENANCE STANDARD OF SWING CIRCLE .......................................................................... 60-8
MAINTENANCE STANDARD OF SWING MACHINERY.................................................................. 60-9
MAINTENANCE STANDARD OF FINAL DRIVE .............................................................................60-11
MAINTENANCE STANDARD OF SPROCKET .............................................................................. 60-13
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING......... 60-14
UNDERCARRIAGE AND FRAME......................................................................................................... 60-16
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION.................................... 60-16
MAINTENANCE STANDARD OF IDLER ....................................................................................... 60-18
MAINTENANCE STANDARD OF TRACK ROLLER....................................................................... 60-20
MAINTENANCE STANDARD OF CARRIER ROLLER ................................................................... 60-22
MAINTENANCE STANDARD OF TRACK SHOE ........................................................................... 60-23
MAINTENANCE STANDARD OF TRIPLE SHOE........................................................................... 60-26
HYDRAULIC SYSTEM.......................................................................................................................... 60-27
MAINTENANCE STANDARD OF MAIN PUMP.............................................................................. 60-27
MAINTENANCE STANDARD OF SWING MOTOR........................................................................ 60-29
MAINTENANCE STANDARD OF TRAVEL MOTOR ...................................................................... 60-32
MAINTENANCE STANDARD OF CONTROL VALVE..................................................................... 60-35
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE ....................... 60-46
MAINTENANCE STANDARD OF TRAVEL PPC VALVE ................................................................ 60-49
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)...... 60-52
MAINTENANCE STANDARD OF SOLENOID VALVE.................................................................... 60-55
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE ........................... 60-56
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .......................................................... 60-57
WORK EQUIPMENT............................................................................................................................. 60-58
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE................................................. 60-58
MAINTENANCE STANDARD OF BOOM CYLINDER .................................................................... 60-67
MAINTENANCE STANDARD OF ARM CYLINDER ....................................................................... 60-68
MAINTENANCE STANDARD OF BUCKET CYLINDER................................................................. 60-69

00-16 PC490LC-11
00 INDEX AND FOREWORD INDEX

80 APPENDIX................................................................................................................................................ 80-1
CONTENTS ............................................................................................................................................ 80-2
AIR CONDITIONER SYSTEM ................................................................................................................ 80-4
PRECAUTIONS FOR REFRIGERANT ............................................................................................ 80-4
AIR CONDITIONER COMPONENT ................................................................................................. 80-5
SPECIFICATIONS OF AIR CONDITIONER ..................................................................................... 80-7
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE ............................................... 80-8
OUTLINE OF REFRIGERATION CYCLE ......................................................................................... 80-9
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .....................................................................80-11
AIR CONDITIONER UNIT...............................................................................................................80-11
COMPONENT PARTS OF AIR CONDITIONER UNIT.................................................................... 80-15
AIR CONDITIONER CONTROLLER .............................................................................................. 80-18
COMPRESSOR ............................................................................................................................. 80-19
CONDENSER ................................................................................................................................ 80-21
RECEIVER DRIER......................................................................................................................... 80-22
SENSORS FOR AIR CONDITIONER SYSTEM............................................................................. 80-23
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER......
.......................................................................................................................................................... 80-25
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER ......... 80-27
AIR CONDITIONER SYSTEM DIAGRAM ............................................................................................. 80-29
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER .................................... 80-30
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS ..
.......................................................................................................................................................... 80-32
TESTING AIR LEAKAGE (DUCT)......................................................................................................... 80-36
METHOD FOR TESTING AIR LEAKAGE (DUCT) ......................................................................... 80-36
EXPLANATION FOR TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .............. 80-38
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE
OF THE MACHINE MONITOR .......................................................................................................... 80-39
TEST VENT (MODE) CHANGEOVER .................................................................................................. 80-40
METHOD FOR TESTING VENT (MODE) CHANGEOVER ............................................................ 80-40
TESTING FRESH/RECIRC AIR CHANGEOVER.................................................................................. 80-42
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER .................................................. 80-42
TEST SUNLIGHT SENSOR.................................................................................................................. 80-43
METHOD FOR TESTING SUNLIGHT SENSOR............................................................................ 80-43
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT.................................................................. 80-44
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT............................ 80-44
TEST RELAYS...................................................................................................................................... 80-45
METHOD FOR TESTING RELAYS ................................................................................................ 80-45
AIR CONDITIONER TROUBLESHOOTING CHART 1 ......................................................................... 80-46
AIR CONDITIONER TROUBLESHOOTING CHART 2 ......................................................................... 80-48
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE........................................................... 80-51
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit............................. 80-54
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit ............................. 80-55
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit ........................................ 80-56
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit ........................................ 80-58
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit.................................................................. 80-60
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit.................................................................. 80-61
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit............................................. 80-62
FAILURE CODE [879EMC] Ventilation Damper Malfunction ................................................................. 80-64
FAILURE CODE [879FMC] Air Mix Damper Malfunction ....................................................................... 80-65
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range ........................................ 80-66
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE).
.......................................................................................................................................................... 80-68
A-2 TROUBLESHOOTING OF COMPRESSOR SYSTEM (AIR IS NOT COOLED) .............................. 80-70
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS
ABNORMAL) ..................................................................................................................................... 80-74
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER............................................... 80-76
TROUBLESHOOTING USING GAUGE PRESSURE............................................................................ 80-78

PC490LC-11 00-17
Komatsu Hydraulic Excavator Pc490lc 11 Usa Shop Manual
Full download: http://manualplace.com/download/komatsu-hydraulic-excavator-pc490lc-11-usa-shop-manual/
INDEX 00 INDEX AND FOREWORD

CONNECTION OF SERVICE TOOL ..................................................................................................... 80-80

METHOD FOR CONNECTING SERVICE TOOL ........................................................................... 80-80
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITION-
ER PIPINGS...................................................................................................................................... 80-82
HANDLE COMPRESSOR OIL .............................................................................................................. 80-84
90 CIRCUIT DIAGRAMS ............................................................................................................................... 90-1
CONTENTS ............................................................................................................................................ 90-2
HYDRAULIC CIRCUIT DIAGRAM .......................................................................................................... 90-3
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .................................................................. 90-3
HYDRAULIC CIRCUIT DIAGRAM (1/2) ........................................................................................... 90-7
HYDRAULIC CIRCUIT DIAGRAM (2/2) ........................................................................................... 90-9
ELECTRICAL CIRCUIT DIAGRAM ........................................................................................................90-11
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM................................................................90-11
ELECTRICAL CIRCUIT DIAGRAM (1/8)........................................................................................ 90-15
ELECTRICAL CIRCUIT DIAGRAM (2/8)........................................................................................ 90-17
ELECTRICAL CIRCUIT DIAGRAM (3/8)........................................................................................ 90-19
ELECTRICAL CIRCUIT DIAGRAM (4/8)........................................................................................ 90-21
ELECTRICAL CIRCUIT DIAGRAM (5/8)........................................................................................ 90-23
ELECTRICAL CIRCUIT DIAGRAM (6/8)........................................................................................ 90-25
ELECTRICAL CIRCUIT DIAGRAM (7/8)........................................................................................ 90-27
ELECTRICAL CIRCUIT DIAGRAM (8/8)........................................................................................ 90-29
INDEX..................................................................................................................................................................1

00-18 PC490LC-11

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